Lubrication system for four-stroke engine

ABSTRACT

A lubrication system for a small lightweight four-stroke engine is disclosed. The lubrication system, provided with a weight at one end of a flexible oil tube inserted into an oil reservoir, is capable of providing a sufficient lubrication to components of the engine which may operate in a horizontal posture, a vertical posture, or any posture therebetween.

BACKGROUND OF THE INVENTION

1. Field of Invention

The invention relates to four-stroke internal combustion engine (ICE)and more particularly to an improved lubrication system for a smalllightweight four-stroke engine.

2. Description of Related Art

Portable power tools such as lawn movers, line trimmers, chain saws asmostly powered by two-stroke ICEs in earlier days. Gradually, two-strokeengines are phased out due to heavy harmful exhaust emissions (e.g.,hydrocarbon (HC)). Nowadays, almost all such portable power tools arepowered by four-stroke ICEs.

Lubrication becomes a very serious problem since portable power toolsare required to operate in a wide range of orientations (i.e., beingtilted or even upside down). There have been numerous suggestions inprior patents for solving this problem. For example, U.S. Pat. No.7,287,508 discloses an engine lubrication method which is incorporatedherein by reference. Thus, continuing improvements in the exploitationof lubrication system for a small lightweight four-stroke engine areconstantly being sought.

SUMMARY OF THE INVENTION

It is therefore one object of the invention to provide a lubricationsystem for a small lightweight four-stroke engine and the lubricationsystem, provided with a weight at one end of a flexible oil tubeinserted into an oil reservoir, is capable of providing a sufficientlubrication to the engine which may operate in a horizontal posture, avertical posture, or any posture therebetween.

The above and other objects, features and advantages of the inventionwill become apparent from the following detailed description taken withthe accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a longitudinal sectional view of a four-stroke engineincorporating a lubrication system according to an embodiment of theinvention;

FIG. 2 is a sectional view taken along line A--A of FIG. 1;

FIG. 3 schematically depicts the check valve case in FIG. 1;

FIG. 4 shows lubricating oil flowing to the crankcase when the pistonmoves upward;

FIG. 5 schematically shows the oil return section;

FIG. 6 schematically depicts the path of lubricating oil flow when thepiston moves downward;

FIG. 7 schematically depicts the path of lubricating oil flow when thepiston moves upward;

FIG. 8 schematically depicts the path of lubricating oil flow when thepiston moves upward when the engine is disposed upright;

FIG. 9 schematically depicts the path of lubricating oil flow when thepiston moves upward when the engine is disposed upside down; and

FIG. 10 schematically depicts the path of lubricating oil flow when thepiston moves downward with an overhead camshaft being mounted in theengine according to another embodiment of the invention.

DETAILED DESCRIPTION OF THE INVENTION

Referring to FIGS. 1 to 9 a four-stroke internal combustion engine (ICE)in accordance with a preferred embodiment of the invention is shown. Theengine is constructed as a lightweight housing and comprises thefollowing components. Each component is discussed in detail below.

A crankcase 10 is provided. An oil reservoir 30 is provided. A checkvalve case 20 is provided in fluid communication with both the crankcase10 and the oil reservoir 30. A first branch tube 60 is in fluidcommunication with both the check valve case 20 and a gaseous oil tube42 of a cam actuation section 40. A first venturi 61 is providedproximate a joining portion of the cam actuation section 40 and thegaseous oil tube 42. Note that the number of the first venturi 61 may bemore than one depending on applications. A second branch tube 70 isprovided between the crankcase 10 and a camshaft case 41 of the camactuation section 40 and is in fluid communication therewith. A secondventuri 71 is provided in the second branch tube 70. The second branchtube 70 has a flexible oil tube 73 having a weight 731 at one end sothat one end of the flexible oil tube 73 may be always immersed in theoil reservoir 30, and a tubing member 72 connected to the flexible oiltube 73 and being in fluid communication therewith.

The crankcase 10 comprises a crank casing 11 formed with a cylinderblock 81 which has a cylinder bore (not numbered) with a piston 15slidably provided therein. A passage 12 is provided on the bottom of thecrankcase 10 and is in fluid communication with the check valve case 20.A crankshaft 13, provided in the crankcase 10, has two sets of bearings131 at both ends and an O-ring 132 at one set of bearings 131. Aconnecting rod 14 is provided to interconnect the crankshaft 13 and thepiston 15.

The check valve case 20 is provided below the crankcase 10. The checkvalve case 20 comprises an oil mist return tube 22 extending from thebottom into the oil reservoir 30 and a check valve 21 having a deflectorplate 211 with an elastic member 212 formed on the top surface of thedeflector plate 211. Oil mist from the crankcase 10 may deflect thedeflector plate 211 to open the check valve 21 when the piston 15 movesdownward. Hence, oil mist enters the check valve case 20. Finally, oilmist flows to the oil reservoir 30 via the oil mist return tube 22. Atthe same time, a small portion of oil mist enters the first branch tube60 which is in fluid communication with the check valve case 20 (seeFIG. 3). To the contrary, the deflector plate 211 returns to itsoriginal position to block the check valve 21 when the piston 15 movesupward. Hence, oil mist is prevented from returning from the oilreservoir 30 to the crankcase 10.

The oil reservoir 30 is provided below the check valve case 20 and is influid communication with the check valve case 20 via the oil mist returntube 22. Liquid lubricating oil is filled in the oil reservoir 30. Theoil reservoir 30 has a volume great larger than that of the check valvecase 20. Heavy liquid oil particles in the oil mist may fall into theoil reservoir 30 and light gaseous oil particles in the oil mist isaccumulated on the oil level of the oil reservoir 30. Further, gaseousoil may enter the gaseous oil tube 42. An open end of the oil mistreturn tube 22 is provided above the center of the oil reservoir 30.

The cam actuation section 40 comprises a lower camshaft case 41 and anupper space 431 with two pushing rods 43 passing through. Twopassageways 432 are provided on the top of the camshaft case 41 with thepushing rods 43 passing through. In addition to the pushing rods 43, acamshaft 44 and a camshaft follower 45 are provided in the cam actuationsection 40. The camshaft 44 comprises a cam 441 and a reduction gear 442coaxially formed therewith. The camshaft 44 and the camshaft follower 45are engaged. The reduction gear 442 is in mesh with a lower gear 46which is in turn formed around the crankshaft 13. The cam actuationsection 40 has a top end in fluid communication with a rocker arm case50 and a bottom end provided with the gaseous oil tube 42. The gaseousoil tube 42 has a bottom end disposed above the oil level of the oilreservoir 30. Gaseous oil rather than liquid oil in the oil reservoir 30may flow to the cam actuation section 40 via the gaseous oil tube 42when the piston 15 moves downward. Oil mist in the camshaft case 41 isdirected along an inner wall 411 of the camshaft case 41 to thepassageways 432 and a second branch tube 701 when the reduction gear 442rotates.

The engine may be implemented as an overhead valve (OHV) engine in theembodiment. Alternatively, the engine may be implemented as an overheadcamshaft (OHC) engine equipped with a cam 443, upper and lower pulleys444 in which one of the pulleys 444 is secured to the cam 443, and abelt 47 passing around the pulleys 444 in another embodiment (see FIG.10).

The rocker arm case 50 is provided in a cylinder head 80 which isaffixed to the cylinder block 81. In the rocker arm case 50 a rocker armmechanism 51 is provided. The rocker arm mechanism 51 comprises a rockerarm 511, a valve 512, and a compression spring 513. The cam 441 mayrotate to actuate the rocker arm mechanism 51 via the camshaft follower45 and the pushing rods 43.

A small portion of oil mist in the check valve case 20 enters the firstventuri 61 via the first branch tube 60. Liquid oil particles in the oilmist are absorbed and nebulized by the first venturi 61. As an end, oilmist with a small amount of liquid oil enters the camshaft case 41.

The second branch tube 70 has an inlet 701 provided in the camshaft case41 proximate the passageway 432. Excess oil mist in the cam actuationsection 40 may enter the crankcase 10 via the second branch tube 70 whenthe piston 15 moves upward. As a result, excess oil mist and liquid oilare prevented from remaining in the cam actuation section 40 and therocker arm case 50. This has the benefit of reducing the consumption oflubricating oil.

The number of the second branch tube 70 may be more than one dependingon applications. Excess oil mist enters the second branch tube 70 whenthe piston 15 moves upward. Also, lubricating oil in the oil reservoir30 flows to the second branch tube 70 via the flexible oil tube 73 andthe tubing member 72. Oil mist in the second branch tube 70 and liquidoil in the tubing member 72 are mixed with air in the second venturi 71.Further, the nebulized oil mist enters the crankcase 10 when the piston15 moves upward.

An oil return section 83 is provided on the top of the cylinder head 80and is separated from the rocker arm case 50 therebelow. The oil returnsection 83 comprises two oil return reservoirs 831 being in fluidcommunication with each other, and a plurality of channels 832interconnecting the oil return section 83 and the rocker arm case 50.Excess oil mist and liquid oil may enter at least one of the channels832 irrespective of the posture of the engine (i.e., horizontal posture,vertical posture, or any posture therebetween). Therefore, the purposeof returning lubricating oil in the rocker arm case 50 can be achieved.

One end of the oil return section 83 is provided with an oil return line84 which has one end in fluid communication with the crankcase 10 sothat the oil return section 83 can communicate with the crankcase 10.Excess oil mist and liquid oil in the rocker arm case 50 may return tothe oil return section 83 via the channels 832. Next, the excess oilmist and liquid oil are inhaled into the crankcase 10 via the oil returnline 84.

A liquid oil and gaseous oil separation chamber 85 is provided betweenthe oil return section 83 and the rocker arm case 50. A porous plate 851for absorbing lubricating oil is provided on the top of the liquid oiland gaseous oil separation chamber 85. A plurality of apertures 852 areprovided on the bottom of the liquid oil and gaseous oil separationchamber 85 and are in fluid communication with the rocker arm case 50.Thus, excess oil mist may enter the liquid oil and gaseous oilseparation chamber 85 via the apertures 852. Liquid oil particles in theoil mist are absorbed by the porous plate 851. Next, the absorbed liquidoil is inhaled into the oil return section 83 via the channels 832.Finally, it is sent to the crankcase 10 via the oil return line 84.Gaseous oil is separated by the liquid oil and gaseous oil separationchamber 85 to form blow-by gas which is again sent to an air filter (notshown) via a breather pipe 86. Clean air from the air filter is inhaledinto a combustion chamber 87 in an air intake cycle of the engine (seeFIG. 1). Also, a spark plug (not numbered) is provided on the top edgeof the combustion chamber 87.

As shown FIG. 6, volume of the crankcase 10 is decreased when the piston15 moves downward. And in turn, oil mist in the crankcase 10 enters thecheck valve case 20. Diameter of the oil mist return tube 22 is muchlarger than that of the first branch tube 60. Hence, a large portion ofoil mist flows toward the oil reservoir 30 via the oil mist return tube22 and only a small portion thereof flows to the first branch tube 60.Liquid oil in the oil mist is formed in the oil mist return tube 22since the flow speed in the oil mist return tube 22 decreases greatly.Hence, the heavy liquid oil flows from the open end of the oil mistreturn tube 22 into the oil reservoir 30. Also, light gaseous oil isaccumulated on the oil level of the oil reservoir 30 and is sent to thegaseous oil tube 42. Also, oil mist may branch from the check valve case20 to flow to the first venturi 61 via the first branch tube 60. Oilmist is then mixed with gaseous oil sent from the gaseous oil tube 42 atthe first venturi 61. The nebulized lubricating oil mixture is sent tothe cam actuation section 40 and the rocker arm case 50 in sequence forlubrication.

As shown in FIGS. 7, 8, and 9, volume of the crankcase 10 is increasedwhen the piston 15 moves upward. And in turn, excess oil mist and liquidoil in the crankcase 40 are inhaled into the second branch tube 70.Also, lubricating oil in the oil reservoir 30 is sucked into theflexible oil tube 73. And in turn, lubricating oil flows to the secondbranch tube 70 via the tubing member 72 which is connected to theflexible oil tube 73. Lubricating oil is nebulized in the second venturi71. The nebulized lubricating oil is then sent to the crankcase 10. Atthe same time, oil mist and liquid oil in the rocker arm case 50 mayenter the oil return reservoirs 831 via the channels 832. Further, aportion of oil mist may enter the liquid oil and gaseous oil separationchamber 85 with liquid oil contained therein being absorbed by theporous plate 851. And in turn, the absorbed liquid oil is sent to theoil return section 83 via the channels 832. All oil mist and liquid oilcontained in the oil return section 83 will be inhaled into the oilreturn line 84 prior to entering the crankcase 10.

Oil mist and liquid oil accumulated in the oil return line 84 and thesecond branch tube 70 will flow from the crankcase 10 to the check valvecase 20 when the piston 15 moves downward.

While the invention herein disclosed has been described by means ofspecific embodiments, numerous modifications and variations could bemade thereto by those skilled in the art without departing from thescope and spirit of the invention set forth in the claims.

1. A single-cylinder, four-stroke cycle, spark ignition internalcombustion engine for mounting on a power tool comprising: a cylinder(81); a piston (15) slidably disposed in the cylinder (81); a crankcase(10) disposed below the cylinder (81); an oil reservoir (30) disposedbelow the crankcase (10); a cam actuation section (40) comprising alower camshaft case (41), an upper space (431), a plurality of pushingrods (43) passing through the upper space (431), a plurality ofpassageways (432) disposed on the top of the camshaft case (41) with thepushing rods (43) passing through, a camshaft (44) with a cam (441) anda reduction gear (442), a camshaft follower (45) engaged with thecamshaft (44), a lower gear (46) secured to the crankshaft (13) andbeing in mesh with the reduction gear (442), and a gaseous oil tube (42)extending to a position above the oil level of the oil reservoir (30);an upper rocker arm case (50) disposed above the cam actuation section(40) and being in fluid communication therewith, the rocker arm case(50) comprising a rocker arm (511) and a valve (512) on the top of thecylinder (81) wherein the rocker arm (511) is adapted to operate byactuating the camshaft follower (45) and the pushing rods (43) byrotating the cam (441); a check valve case (20) disposed below thecrankcase (10) and being in fluid communication with the crankcase (10)and the oil reservoir (30), the check valve case (20) having an oil mistreturn tube (22) extending into the oil reservoir (30), and a checkvalve (21); a first branch tube (60) being in fluid communication withthe check valve case (20) and the gaseous oil tube (42), the firstbranch tube (60) having a diameter larger than that of the oil mistreturn tube (22); a first venturi (61) disposed in the gaseous oil tube(42) externally of the oil reservoir (30); a second branch tube (70)interconnecting the crankcase (10) and the cam actuation section (40)and being in fluid communication therewith; a second venturi (71)disposed in the second branch tube (70); a flexible oil tube (73) havinga weight (731) at one end immersed in the oil reservoir (30); a tubingmember (72) connected to the flexible oil tube (73); a crankshaft (13)rotatably disposed in the crankcase (10); a connecting rod (14)interconnecting the crankshaft (13) and the piston (15); an oil returnsection (83) disposed on the top of the rocker arm case (50), the oilreturn section (83) comprising a plurality of oil return reservoirs(831) being in fluid communication with each other, and a plurality ofchannels (832) interconnecting the oil return section (83) and therocker arm case (50); an oil return line (84) interconnecting the oilreturn section (83) and the crankcase (10); and a liquid oil and gaseousoil separation chamber (85) disposed between the oil return section (83)and the rocker arm case (50), the liquid oil and gaseous oil separationchamber (85) being in fluid communication with the rocker arm case (50)and including a top porous plate (851) for absorbing lubricating oil;wherein irrespective of the posture of the internal combustion engine inresponse to moving the piston (15) in a first direction to decrease thevolume of the crankcase (10), oil mist in the crankcase (10) enters thecheck valve case (20) a first portion of the oil mist flows to the oilreservoir (30) via the oil mist return tube (22), a second portion ofthe oil mist being smaller than the first portion thereof in volumeflows to the first branch tube (60), liquid oil in the oil mist isformed in the oil mist return tube (22) and flows into the oil reservoir(30), gaseous oil in the oil mist is accumulated on the oil level of theoil reservoir (30) and flows to the gaseous oil tube (42), the oil mistalso branches from the check valve case (20) to flow to the firstventuri (61) via the first branch tube (60), and the oil mist is mixedwith the gaseous oil from the gaseous oil tube (42) at the first venturi(61) to form a nebulized mixture which is sent to the cam actuationsection (40) and the rocker arm case (50) in sequence for lubrication;and wherein irrespective of the posture of the internal combustionengine in response to moving the piston (15) in a second direction toincrease the volume of the crankcase (10), excess oil mist and liquidoil in the crankcase (40) are inhaled into the second branch tube (70),lubricating oil in the oil reservoir (30) is sucked into the flexibleoil tube (73) and flows to the second branch tube (70) via the tubingmember (72), the lubricating oil is nebulized in the second venturi (71)and flows to the crankcase (10), oil mist and liquid oil in the rockerarm case (50) enter the oil return reservoirs (831) via the channels(832), a portion of oil mist enters the liquid oil and gaseous oilseparation chamber (85) with liquid oil contained therein being absorbedby the porous plate (851), the absorbed liquid oil is sent to the oilreturn section (83) via the channels (832), the oil mist and the liquidoil contained in the oil return section (83) are inhaled into the oilreturn line (84) prior to entering the crankcase (10), and the oil mistand the liquid oil in the oil return line (84) and the second branchtube (70) flow from the crankcase (10) to the check valve case (20).